Spring Assembly Having Continuous Bands of Springs

ABSTRACT

A bedding or seating product comprising a spring assembly, including a plurality of bands of coil springs. If desired, one or two rectangular border wires may be clipped to the spring assembly. Each band of coil springs is made of a single piece of wire shaped to define a plurality of coil springs connected by innerconnecting segments. Each of the coil springs has a tapered central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns. The bands of springs may be arranged in any desired orientation and may be connected by helical lacing wires.

BACKGROUND OF THE INVENTION

This invention relates generally to bedding or seating products and, more particularly, to a spring interior, spring assembly or innerspring for a mattress.

Traditionally, spring assemblies for mattresses have consisted of a plurality of spaced parallel rows of helical coil springs mounted between border wires; coil springs adjacent the border wires being attached thereto via helical lacing wires, sheet metal clips or other connectors. The upper and lower end turns of adjacent coil springs are generally connected to each other by helical lacing wires. Coil springs are arranged in longitudinally extending columns and transversely extending rows. Padding and upholstery commonly are secured to opposed surfaces of the spring assembly, thereby resulting in what is known in the industry as a two-sided mattress for use on either side.

Spring assemblies have also been developed having only one border wire to which the end turns of the outermost coil springs are secured. After padding and/or other materials are placed over the upper surface of the spring assembly in which the border wire is located, an upholstered covering is sewn or secured around the spring assembly and cushioning materials, thereby creating what is known in the industry as a one-sided or single-sided mattress.

Another form of spring assembly for use in a bedding or seating product comprises a plurality of longitudinally extending bands of springs disposed side-by-side and connected by helical lacing wires which extend transversely of the bands and embrace portions of the bands. One kind of band, which is the subject of British Patent No. 2,143,371, will hereinafter be referred to as a band of interlocked or interlaced springs. Each such band comprises a single length of spring wire shaped to form a plurality of individual coil springs arranged in a row, one end turn of each coil spring lying adjacent to a top face of the band and the other end turn of each coil spring lying adjacent to a bottom face of the band. Each coil spring has a central portion of a uniform diameter and is of a rotational hand opposite to the rotational hand of the adjacent coils immediately before and after it in the row and is joined to the adjacent coil springs by a plurality of innerconnecting segments of wire integral with the coil springs. One of the pair of innerconnecting segments is located in the bottom face of the band and the other of the pair of innerconnecting segments is located in the top face of the band. Each innerconnecting segment comprises a bridging portion between adjacent coils, which bridging portion extends lengthwise of the row.

When bands of interlocked springs of the type described hereinabove are assembled to form a spring interior, they are disposed side-by-side and interconnected with helical lacing wires, some of which lie in the top face of the spring interior and others of which lie in the bottom face of the spring interior. The top and bottom faces of the spring interior are the faces defined by the top and bottom faces of the bands of springs incorporated into the spring interior. Each helical lacing wire extends across the bands of springs and embraces portions of wires of the bands that extend transversely of the bands from the ends of the bridging portions of the innerconnecting segments. In the top and bottom faces of the spring interior, the helical lacing wires are disposed at uniform intervals along the bands of springs such that there are two coil springs disposed in the interval between each helical lacing wire and the next adjacent helical lacing wire.

It is customary for a bedding spring interior to be incorporated into an upholstered article. In such an article, at least one of the main faces of the spring interior is covered by a layer or layers of padding. This, in turn, is covered by a cover made of sheet material, such as ticking or upholstery fabric. U.S. Pat. No. 5,649,332 discloses such a product.

Historically, innersprings made of bands of continuous wire have consisted of cylindrical type coil springs with an even compression rate throughout most of the spring. It would be desirable to achieve a similar compression rate and feel with fewer coil springs or wire of a smaller gauge to reduce the amount of wire in the unit. It further would be desirable to prevent material, i.e., the padding on top of the innerspring from entering the barrel of the coil springs.

SUMMARY OF THE INVENTION

This invention comprises a bedding or seating product comprising a spring assembly, padding overlying the spring assembly and a fabric covering encasing the padding and spring assembly. The product has a longitudinal dimension and a transverse dimension, the longitudinal dimension usually being greater than the transverse dimension. However, the longitudinal and transverse dimensions may be the same.

The spring assembly has top and bottom main faces and comprises upper and lower generally rectangular border wires, each border wire having two parallel sides and two parallel ends. The spring assembly further comprises a plurality of generally parallel bands of springs. The bands may extend longitudinally or alternatively transversely. Each of the bands of springs comprises a single length of wire shaped to form a plurality of coil springs arranged in a row. Each of the coil springs has a central spiral portion defining a central spring axis and terminates at opposed ends with upper and lower end turns lying adjacent the top and bottom main faces of the spring assembly. Each of the coil springs is of a hand opposite to the hand of the adjacent coil springs of the same row and is interlaced with the adjacent coil springs of the same row. Each of the coil springs is joined to the adjacent coil springs by innerconnecting segments integral with the coil springs, one of the innerconnecting segments being located substantially in the top face of the band and the other of the innerconnecting segments being located substantially in the bottom face of the band. Each innerconnecting segment comprises a pair of offset bridging portions which extend lengthwise of the row and are connected to each other with a center portion. The bands are interconnected with helical lacing wires lying in the top and bottom main faces of the spring assembly and extending transversely across the bands. Each helical lacing wire encircles portions of the bands from the ends of the bridging portions thereof, two coil springs being in the interval between adjacent helical lacing wires in the same main face of the spring assembly.

According to another aspect of the present invention, the bedding or seating product comprises a spring assembly having top and bottom main faces and comprising a plurality of generally parallel bands of springs surrounded by upper and lower border wires. Each of the bands of springs comprises a single length of wire shaped to form a plurality of coil springs arranged in a row. Each of the coil springs has a central spiral portion defining a central spring axis and terminates at opposed ends with upper and lower end turns lying adjacent the top and bottom main faces of the spring assembly. Each of the coil springs is of a hand opposite to the hand of the adjacent coil springs of the same row and is interlaced with the adjacent coil springs of the same row. Each of the coil springs is joined to the adjacent coil springs by innerconnecting segments integral with the coil springs, one of the innerconnecting segments being located substantially in the top face of the band and the other of the innerconnecting segments being located substantially in the bottom face of the band. Each innerconnecting segment comprises a pair of end portions and a pair of offset bridging portions which extend lengthwise of the row and are connected to each other with a center portion parallel the end portions. The bands are interconnected with helical lacing wires lying in the top and bottom faces of the spring assembly and extending transversely across the bands. Each helical lacing wire encircles the end portions of the innerconnecting segments of the bands, two coil springs being in the interval between adjacent helical lacing wires in the same main face of the spring assembly.

Although several types of spring assemblies have been described, the spring assembly of this invention may be used in any bedding or seating product. For example, padding may be on both sides of any of the spring assemblies disclosed herein and encased by the fabric covering.

BRIEF DESCRIPTION OF THE DRAWINGS

The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

FIG. 1 is a perspective view, partially broken away, of a mattress according to one embodiment;

FIG. 2 is an enlarged perspective view illustrating a portion of the spring assembly of the mattress of FIG. 1;

FIG. 3 is a side elevational view of a portion of a band of springs of the spring assembly of FIG. 1;

FIG. 4 is a top plan view illustrating a portion of the spring assembly of FIG. 1;

FIG. 5 is a top plan view illustrating a portion of the spring assembly of FIG. 1;

FIG. 6 is a top plan view illustrating a portion of an alternative embodiment of spring assembly;

FIG. 7 is a partially disassembled view illustrating a portion of an alternative embodiment of product; and

FIG. 8 is an enlarged perspective view illustrating a portion of the spring assembly of the product of FIG. 7.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings and, particularly to FIG. 1, a bedding or seating product in the form of a mattress 10, according to one embodiment of this invention, is illustrated. The present invention is not intended to be limited to bedding product, such as mattresses; it may be used in seating or other related products. As shown in FIG. 1, the mattress 10 has a longitudinal dimension or length L, a transverse dimension or width W and a height H. Although the length L is shown as being greater than the width W, they may be identical.

The mattress 10 comprises a spring core or spring assembly 12 comprising a plurality of parallel bands of springs 14 held together with helical lacing wires 16. The spring assembly 12 further comprises generally rectangular upper and lower border wires 17, 18, respectively. The upper border wire 17 is located generally in a top or upper main face 4 of the spring assembly 12, and the lower border wire 18 is located generally in a bottom or lower main face 6 of the spring assembly 12. See FIG. 2. In the embodiment shown in FIGS. 1-5, the bands of springs 14 extend longitudinally or from head-to-foot and the helical lacing wires 16 extend transversely or from side-to-side. Padding 20 overlies the spring assembly 12, and a fabric covering 22 surrounds the padding 20 and spring assembly 12. The padding 20 may be on one or both sides of the product 10.

FIG. 1 illustrates a two-sided spring assembly 12 having upper and lower generally rectangular steel border wires 17, 18. Each border wire has two parallel sides 24, 24 and two parallel ends 26, 26. The parallel sides 24, 24 are longer than the parallel ends 26, 26 in the embodiment illustrated. However, they may be the same size.

As best seen in FIG. 2, each of the bands of springs 14 is made of one piece of wire shaped to form a plurality of coil springs 28 arranged in a row 30. In the embodiment illustrated in FIGS. 1-5, the bands 14 of coil springs 28 extend longitudinally and are secured together with transversely extending helical lacing wires 16. As shown in FIGS. 1, 4 and 5, the bands 14 of coil springs 28 are secured to the upper and lower border wires 17, 18 with conventional sheet metal clips 32 or any other conventional fastener.

As shown in FIGS. 2 and 3, each coil spring 28 comprises about two and one-half turns of wire including a central spiral portion 34 defining a central spring axis A and terminating at opposed ends with upper and lower unknotted end turns 36, 38, respectively. The upper and lower end turns 36, 38 of each coil spring lie adjacent to top and bottom faces 40, 42, respectively, of the band 14 of coil springs 28. Each coil spring 28, such as that numbered 28 a (FIG. 2), is so coiled as to have a hand opposite to the hand of the adjacent coil springs, such as coil springs 28 b and 28 c, for example.

Each coil spring 28 is joined to the adjacent coil springs 28 by two innerconnecting segments 44, 46 of the wire integral with the coil springs. One of the innerconnecting segments 44 is in the top face 40 of the band 14, and the other innerconnecting segment 46 is in the bottom face 42 of the band 14. For example, as shown in FIG. 2, coil spring 28 a is connected to coil spring 28 b by one of the innerconnecting segments 44, which is in the top face 40 of the band 14 and to coil spring 28 c by one of the innerconnecting segments 46, which is in the bottom face 42 of the band 14.

Each innerconnecting segment 44, 46 comprises a pair of offset bridging portions 48 which extend lengthwise of the row 30 of coil springs 28 in a parallel manner, and a center portion 50 extending between the offset bridging portions 48 and two end portions 52 which extend parallel the center portion 50 and perpendicular to the offset bridging portions 48. The end portions 52 of each innerconnecting segment 44, 46 lie in the top and bottom faces 40, 42, respectively, of the band 14. Adjacent end portions 52 of adjacent innerconnecting segments 44, 46 are encircled by one of the helical lacing wires 16 which extend generally perpendicular to the direction of the bands 14 of springs. The helical lacing wires 16 are located generally in the top and bottom main faces 4, 6, respectively, of the spring assembly 12. The center portion 50 of each innerconnecting segment 44, 46 connects the two offset bridging portions 48 of each innerconnecting segment and is generally parallel the two end portions 52 of each innerconnecting segment.

Each of the innerconnecting segments 44, 46 of the band 14 of coil springs 28 is shaped or configured to provide a maximum amount of support to a person lying on top of the innerspring assembly 12. This configuration of the innerconnecting segments 44, 46 of the bands 14 helps prevent dimpling or indentations in the padding 20 formed from external pressure applied by a person lying or sitting on the mattress or product, thereby potentially causing the padding 20 to sink into the interior of the innerspring assembly 12.

As shown in FIG. 3, the central spiral portion or barrel 34 of each of the coil springs 28 is conically shaped (not cylindrical). For example, as shown in FIG. 3, the upper end of the central spiral portion or barrel 34 of coil spring 28 a is smaller in diameter than the lower end. As shown in FIG. 3, D1 is less than D2. In other words, in the coil spring 28 a, the lower revolution has a larger diameter than the upper revolution of the central spiral portion or barrel 34 of the coil spring. The coil springs 28 are arranged such that adjacent coil springs are inverted relative to each other. For example, coil spring 28 c, immediately to the right of coil spring 28 a in FIG. 3, has a conical central spiral portion or barrel 34 with the upper revolution being of a diameter larger than the diameter of the lower revolution. Thus, this coil spring is inverted relative to its adjacent coil springs. This configuration of coil springs within a band of springs allows one coil spring to compress from the top to the bottom while the coil spring adjacent to it compresses from the bottom to the top. The coil springs being interlaced causes them to provide additional support to an end user of the product.

FIG. 4 illustrates a portion of the upper main face 4 of the spring assembly 12 as shown from above. One of the bridging portions 48 of the innerconnecting segments 44 are shown clipped to the sides 24 of upper border wire 17. Similarly, at the end of each band of springs 14, part of the center portions 50 of the innerconnecting segments 44 are clipped to the ends 26 of the upper border wire 17 using clips 32.

FIG. 5 illustrates a portion of the lower main face 6 of the spring assembly 12, as shown from above. One of the bridging portions 48 of the outermost row of lower innerconnecting segments 46 are shown clipped to one of the sides 24 of lower border wire 18. Similarly, at the end of each band of springs 14, part of the center portions 50 of the lower innerconnecting segments 46 are clipped to the ends 26 of the lower border wire 18 using clips 32.

FIG. 6 illustrates a top view of an alternative embodiment of product 10 a having a spring assembly 12 a in which the bands 14 a of coil springs 28 a extend transversely or from side-to-side, rather than from head-to-foot. In this embodiment, the helical lacing wires 16 a extend parallel the sides 24 a of the border wires 17 a, 18 a and the bands of springs 14 a extend parallel the ends 26 a of the border wires or from side-to-side. By cutting the center portion 50 of one of the innerconnecting segments 44 in half, one half 54 of one of the center portions 50 may be clipped by clip 32 to one of the sides 24 a of upper border wire 17 a, and the other half 56 of the center portion 50 clipped at the opposite side of the product 10 a to the other side 24 a of upper border wire 17 a. In other words, different orientations of the coil springs and helical lacing wires within the spring assembly are possible within the scope of the present invention.

The spring assembly 12 of mattress 10 is generally manufactured by a supplier, who then ships it to an assembler. The assembler adds to the spring assembly 12 padding 20, and covers the components with upholstery 22 to make a completed product.

One advantage of the spring assembly and associated bedding or seating product, such as a mattress according to this invention, is that each of the bands of springs is uniquely configured to use fewer coils or smaller wire gauges to a similar compression rate and feel when compared to existing continuous wire units.

FIGS. 7 and 8 illustrate an alternative embodiment of product 10 b having a spring assembly 12 b in which the bands 14 b of coil springs 28 bb extend longitudinally or from head-to-foot rather than transversely or from side-to-side. In this embodiment, the bands of springs 14 b may alternatively extend from side-to-side like the embodiment shown in FIG. 6, but with no border wires. In this embodiment, spring assembly 12 b is encased within a rectangular foam border 58 comprising opposed side panels 60 and end panels 62 joined together. A rectangular top panel 64 and a rectangular bottom panel 66 further encase the spring assembly 12 b and may be secured to the foam border 58 in any known manner. If desired, the top and/or bottom panel may be omitted.

FIG. 8 illustrates a portion of spring assembly 12 b which is identical to spring assembly 12 shown in FIGS. 1-5 without the border wires and with the ends of each band of springs ending in a loop 68. For convenience, the same numbers have been used.

One of ordinary skill in the art will readily recognize that the alternative embodiments of the mattress shown and described herein are exemplary of a wide variety of alternative configurations that are readily possible within the scope of this invention.

From the above disclosure of the general principles of the present invention, and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, we desire to be limited only by the scope of the following claims and equivalents thereof. 

We claim:
 1. A bedding or seating product having a longitudinal dimension and a transverse dimension, said product comprising: a spring assembly having top and bottom main faces and comprising a plurality of generally parallel bands of springs, each of the bands of springs comprising a single length of wire shaped to form a plurality of coil springs arranged in a row, each of the coil springs having a central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns lying adjacent the top and bottom main faces of the spring assembly, each of the coil springs being of a hand opposite to the hand of the adjacent coil springs of the same row and being interlaced with the adjacent coil springs of the same row, each of the coil springs being joined to the adjacent coil springs by innerconnecting segments integral with the coil springs, one of the innerconnecting segments being located substantially in the top face of the band and the other of the innerconnecting segments being located substantially in the bottom face of the band, each innerconnecting segment comprising a pair of offset bridging portions which extend lengthwise of the row and are connected to each other with a center portion, the bands being interconnected with helical lacing wires lying in the top and bottom main faces of the spring assembly and extending transversely across the bands, each helical lacing wire encircling portions of the bands from the ends of the bridging portions thereof, two coil springs being in the interval between adjacent helical lacing wires in the same main face of the spring assembly; padding overlaying the spring interior; a fabric covering encasing the padding and spring interior.
 2. A bedding or seating product having a longitudinal dimension and a transverse dimension, said product comprising: a spring assembly having top and bottom main faces and comprising a plurality of generally parallel bands of springs, each of the bands of springs comprising a single length of wire shaped to form a plurality of coil springs arranged in a row, each of the coil springs having a central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns lying adjacent the top and bottom main faces of the spring assembly, each of the coil springs being of a hand opposite to the hand of the adjacent coil springs of the same row and being interlaced with the adjacent coil springs of the same row, each of the coil springs being joined to the adjacent coil springs by innerconnecting segments integral with the coil springs, one of the innerconnecting segments being located substantially in the top face of the band and the other of the innerconnecting segments being located substantially in the bottom face of the band, each innerconnecting segment comprising a pair of offset bridging portions which extend lengthwise of the row and are connected to each other with a center portion, the bands being interconnected with helical lacing wires lying in the top and bottom faces of the spring assembly and extending transversely across the bands, each helical lacing wire encircling portions of the bands from the ends of the bridging portions thereof, two coil springs being in the interval between adjacent helical lacing wires in the same main face of the spring assembly.
 3. The product of claim 2 further comprising upper and lower border wires.
 4. The product of claim 2 wherein the bands of springs extend longitudinally.
 5. The product of claim 2 wherein the bands of springs extend transversely.
 6. The product of claim 2 wherein the end turns of the outermost coil springs are clipped to the border wires with clips.
 7. The product of claim 2 wherein the central spiral portions of the coil springs are tapered.
 8. The product of claim 7 wherein the central spiral portions of adjacent coil springs are inverted.
 9. The product of claim 7 wherein the central spring axes of adjacent coil springs are not parallel.
 10. A bedding or seating product having a longitudinal dimension and a transverse dimension, said product comprising: a spring assembly having top and bottom main faces and comprising a plurality of generally parallel bands of springs, each of the bands of springs comprising a single length of wire shaped to form a plurality of coil springs arranged in a row, each of the coil springs having a tapered central spiral portion defining a central spring axis and terminating at opposed ends with upper and lower end turns lying adjacent the top and bottom main faces of the spring assembly, the central spiral portions of adjacent coil springs being inverted and each of the coil springs being of a hand opposite to the hand of the adjacent coil springs of the same row and being interlaced with the adjacent coil springs of the same row, each of the coil springs being joined to the adjacent coil springs by innerconnecting segments integral with the coil springs, one of the innerconnecting segments being located substantially in the top face of the band and the other of the innerconnecting segments being located substantially in the bottom face of the band, the bands being interconnected with helical lacing wires lying in the top and bottom faces of the spring assembly and extending transversely across the bands, each helical lacing wire encircling portions of the innerconnecting segments of the bands, two coil springs being in the interval between adjacent helical lacing wires in the same main face of the spring assembly.
 11. The product of claim 10 further comprising upper and lower border wires.
 12. The product of claim 10 wherein the bands of springs extend longitudinally.
 13. The product of claim 10 wherein the bands of springs extend transversely.
 14. The product of claim 10 wherein portions of the innerconnecting segments of the bands of springs are clipped to the border wires with clips.
 15. The product of claim 10 wherein each innerconnecting segment comprising a pair of end portions and a pair of offset bridging portions which extend lengthwise of the row and are connected to each other with a center portion.
 16. The product of claim 15 wherein the center portion of each innerconnecting segment is generally parallel the end portions of the innerconnecting segment.
 17. The product of claim 15 wherein the central spring axes of adjacent coil springs are not parallel.
 18. The product of claim 10 wherein the longitudinal dimension and the transverse dimension are different.
 19. The product of claim 18 wherein the longitudinal dimension is greater than the transverse dimension.
 20. The product of claim 10 further comprising padding and an upholstered covering. 